Roughcutting the arches

Referring to the anatomy illustration of the pigeonhole unit (page 108), outline the shape of the arches on a piece of %-inch plywood, cut it out, and smooth the edges to fashion a template that you will use to make a routing jig (step 2). Before assembling the jig, use the template to outline six copies of the shape on your arch stock. Cut out the arches to within H inch of your cutting lines using the band saw. To keep the blade from binding in the kerfs, make a series of release cuts through the waste, stopping % inch from the lines. Then saw along the waste side of the lines, feeding the work-piece with both hands (right). Make sure that neither hand is in line with the blade.

Arch stock

Guide piece

Arch blank

Template

Guide piece

Arch blank

Template

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